Sound-attenuation system

ABSTRACT

A sound attenuation system can include a first end that can include a shaft and a flange, the flange can be coupled to the shaft, and a second end that can include a filter stem and a cap. The filter stem can have a hole. The cap can have a first position in which the cap occludes the hole and can have a second position in which the cap is clear of the hole.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/566,699, filed Oct. 14, 2017 by David M. Chenal and titled “Soundattenuation apparatus and method” (which issues as U.S. Pat. No.10,940,043 on Mar. 9, 2021), which is a national-phase filing of, andclaims priority benefit of, PCT Patent Application No.PCT/US2016/027820, filed Apr. 15, 2016 by David M. Chenal and titled“Sound attenuation,” which claims the benefit of priority of U.S.Provisional Patent Application Ser. No. 62/148,237, filed Apr. 16, 2015,each of which is hereby incorporated by reference herein in itsentirety. This application is also related to U.S. Pat. No. 9,603,746,which issued Mar. 28, 2017 to David M. Chenal, titled “Soundattenuation.”.

FIELD OF THE INVENTION

The present invention relates to devices and methods for shaping/sizingan earpiece foam part and optionally attaching the shaped part to anearphone or earplug piece and associated storage container, and inparticular to a system and method for storing, sizing, and cleaningearphones and earplugs and the foam tips thereof.

BACKGROUND OF THE INVENTION

An earplug may be inserted into an ear canal of a user to attenuatesound. An earplug user may desire a particular earplug feature, such asa comfortable configuration, ease of insertion or removal from the earcanal, or an ear canal conforming feature. The earplug may be used invarious environments where sound may be undesired or harmful to theauditory health of the user, such as military, music or concerts,industrial, or construction environments. Current techniques areinadequate for retaining the earplug in the ear canal. U.S. Pat. No.8,161,975 refers to a dual mode impulse noise protecting earplug.

SUMMARY OF THE INVENTION

The present invention provides an earpiece-foam shaping/sizing systemthat includes a bottom portion configured to store an earpiece, whereinthe earpiece includes at least a foam portion, a cap configured toremovably couple to the bottom portion; and a sizer configured toreceive the foam portion in order to compress the foam portion such thatthe foam portion is configured to fit inside an ear of a user.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numeralsmay describe similar components in different views. Like numerals havingdifferent letter suffixes may represent different instances of similarcomponents. The drawings illustrate generally, by way of example, butnot by way of limitation, various embodiments discussed in the presentdocument.

FIG. 1A includes a view of an example of an earplug.

FIG. 1B includes a cross-section view of an example of an earplug.

FIG. 2A includes a view of an example of a sound filter.

FIG. 2B includes a view of an example of a sound filter.

FIG. 3A includes a view of an example of a portion of an earplug.

FIG. 3B includes an end view of an example of a portion of an earplug.

FIG. 4 illustrates an example of a foam body.

FIGS. 5A, 5B, and 5C illustrate a portion of an earplug, according tosome examples.

FIG. 6 illustrates an example of a tool.

FIG. 7 illustrates an assembly method, according to an example.

FIG. 8 illustrates an example of a sound filter.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1A includes a view of an example of an earplug 102. The earplug 102includes a first end 108 and a second end 116. The earplug 102 includesa flange 104, a foam body 106A, a cap 110A, a knob 112A, a port boss114, a base plate 118, a joint 120, and a hole 122. The knob 112A iscoupled to the cap 110A. The knob 112A helps the user to grasp theearplug 102.

FIG. 1B includes a cross-section view of a portion of an example of theearplug 102. The earplug 102 includes a tube (e.g., a shaft 124 having abore 130). The shaft 124 includes a receiver end 126 and an emitter end128. The bore 130 terminates at the receiver end 126 and at the emitterend 128. The flange 104 is coupled to the shaft 124.

The earplug 102 includes a sound filter, a portion of which isillustrated in the figure. The sound filter includes a filter stem 132.The filter stem 132 includes an inlet end 134 and an outlet end 136. Thefilter stem 132 includes the hole 122. The hole 122 terminates at theinlet end 134 and at the outlet end 136. The hole 122 extends throughthe port boss 114. The hole 122 includes a first chamber 166 having afirst diameter and a second chamber 168 having a second diameter. In theexample of FIG. 1B, the first diameter is less than the second diameter.The filter stem 132 is configured to be at least partially inside of thebore 130. The outlet end 136 is configured to be inside the bore 130. Inan example, the filter stem 132 has a press fit with the bore 130, suchthat filter stem 132 can expand the bore 130. As such, the press fit canuse friction to secure the filter stem 132 in the bore 130. A portion ofthe filter stem 132 is tapered, such as at the outlet end 136 as shownin the example of FIG. 1B. The taper at the outlet end 136 can aid theinsertion of the filter stem 132 into the bore 130 in the assembly ofthe earplug 102. The foam body 106A abuts the base plate 118.

In some examples, the first chamber 166 and second chamber 168 can bepositioned, sized, or shaped in different configurations within the hole122. The first diameter can be greater than the second diameter. Thehole 122 can include one or more chambers (e.g., one, two, three, four,or more).

The shaft 124 has a first elastic material. The first elastic materialhas a first durometer. In one example, shaft 124 includes silicone. Thefilter stem 132 has a second elastic material. The second elasticmaterial has a second durometer. The first durometer is less than thesecond durometer. A shape of the ear canal can be non-uniform along itslength. The shaft 124 can bend when inserted into the ear canal. Thefirst durometer is configured to allow the shaft 124 to conform to theshape of the ear canal. The present techniques can reduce pressureexerted on the ear canal by the earplug 102. This is because the firstmaterial conforms to the ear canal's shape, rather than a more rigidmaterial such as the second material. The second durometer is configuredto have the filter stem 132 substantially retain its shape (e.g., thefilter stem 132 is more rigid than the shaft 124). In one example, thebase plate 118 has the second durometer.

In one example, shaft 124 has a durometer of between 30 and 40 on theshore A scale. In one example, shaft 124 has a durometer of 35 on theshore A scale.

The earplug 102 is inserted into an ear canal of a user to attenuatesound. The user holds the cap 110A of the earplug 102 for inserting thefirst end 108 into the ear canal. In an example, the user can hold thecap 110A between a finger and thumb. The finger can engage the knob112A. The thumb can cover the cavity 138. A portion of the thumb canocclude the hole 122 during the insertion of the earplug 102 into theear canal. In an example, the user presses the thumb onto a portion ofthe port boss 114 to occlude the hole 122. With the thumb occluding thehole 122, the user can hear that the earplug 102 is positioned at alocation that attenuates sound.

In some examples, the knob 112A has various shapes and sizes. The knob112A is rounded, such as a hemisphere in the example of FIG. 1A. Theknob 112A is a cylinder or a box according to some examples. The knob112A can include multiple units, such as multiple bumps on a surface ofthe cap 110A configured to help the user grasp the earplug 102. Knob112A can provide tactile feedback to aid the user in gripping andpositioning earplug 102. In one example, knob 112A can provide audiblefeedback to aid the user positioning earplug 102 with the ear canal. Asoft ‘pop’ can be felt and heard when the knob 112A is moved into aposition to occlude the port boss.

In some examples, the knob 112A is optional. In various examples, anelbow component or interface device can engage with the port boss 114,with filter stem 132, or with bore 130 to allow attachment of a headset,a hearing aid, an interruptible foldback (IFB) device, or atelecommunications device.

The base plate 118 is configured to maintain a position of the foam body106A along the length of the shaft 124. The filter stem 132 ispositioned inside the bore 130, such that the receiver end 126 isconfigured to abut the base plate 118.

Flange 98A, in the example shown in FIG. 1B, has a radius on an inneredge. The outer edge is squared and, in some examples, provides afeature that can engage a prominence on the inner side of the earanatomy and facilitate device retention. In some users, flange 98Aengages the tragus or other anatomic feature. In some configurations,flange 98A is fabricated of a material to mitigate or eliminate abrasionof skin surfaces proximate the foam body. Flange 98A can have a thincross-section that is configured to deflect under a small force.

In one example, flange 96 is provided at an end of shaft 124. Flange 96can facilitate retention of foam body 106A on shaft 124 or otherwiselimit relative movement, in an axial direction, as to foam body 106A andshaft 124. In one example, flange 96 can be configured to provide afriction fit to retain a filter stem 132 or retain a headset, hearingaid, IFB, or telecommunications device. Flange 96 can take the form of aring or a raised feature.

FIG. 2A includes a view of an example of the sound filter 170. The cap110A can be in one or more positions. The cap 110A can be in a firstposition, as shown in FIG. 2A, such that the cap 110A occludes the hole122 (not visible in this view). The filter stem 132 is coupled to thebase plate 118. The cap 110A is coupled to the base plate 118 by thejoint 120. The cap 110A can be moved from the first position, such as bythe user lifting the cap 110A. The joint 120 can include one or morecomponents. In an example, the joint 120 is movable, and can bedescribed as a hinge configured to allow the cap 110A to be in the oneor more positions.

In an example, the joint 120 is a living hinge. The living hinge canhave the same material as two rigid members it connects.

In the first position, a gap 148 is between the base plate 118 and thecap 110A. A height of the gap 148 is the axial distance between the baseplate 118 and the cap 110A, as shown in FIG. 2A. The gap 148 isconfigured to aid the user in moving the cap 110A from the firstposition. The height is configured such that a finger or fingernail canengage and separate the cap 110A from the port boss 114. The base plate118 includes a notch 164. The notch 164 is configured to aid the user inmoving the cap 110A, such as to allow easier access for a user's thumbor finger. The gap 148 and the notch 164 can each aid the user in movingthe cap 110A individually or jointly. The port boss 114 is positioned atthe inlet end 134 (not visible in this view), such that the port boss114 includes a portion of the hole 122. In an example, the port boss 114includes a ring 174. The ring 174 can be raised on the port boss 114 orrecessed into the port boss 114.

FIG. 2B includes a view of an example of the sound filter 170. The cap110A can be in a second position, as shown in FIG. 2B, such that the cap110A is clear of the hole 122. The cap 110A includes a cavity 138. Thecavity 138 has a cavity diameter 140. The port boss 114 has an outerdiameter 144. The cavity diameter 140 corresponds to the outer diameter144. In the second position, there is a space 172 between the base plate118 and the cap 110A. The space 172 can allow the user to grasp the cap110A.

Outer diameter 144 and port boss 114 can provide an interference fit aidin retention of cap 110A in an occluded position. In one example, ring174 can provide an interference fit with cap 110A.

In an example, in the first position, an angle between the base plate118 and the cap 110A can be 0 degrees (e.g., the base plate 118 isparallel to the cap 110A). The angle can be along the space 172, such asshown in FIG. 2B. In an example, the first position can include an anglegreater than 0 degrees, such that the cap 110A occludes the hole 122. Inan example of the second position, the angle between the base plate 118and the cap 110A can range from greater than zero degrees to 180 degreesor more, such that the cap 110A is clear of the hole 122. In an example,when the angle is 90 degrees, the cap 110A is perpendicular to the baseplate 118. The position of the cap 110A can be moved along the space172.

The space 172 of the second position can be configured to allow anattachment to couple to the port boss 114. The attachment can be aspeaker, a transducer, tubing, or another unit. The ring 174 can aid incoupling (e.g., securing) the attachment to the port boss 114.

In the first position (e.g., FIG. 2A), the knob 112A is configured toaid in attenuating sound. In an example, a thickness of the knob 112A isconfigured to increase sound blockage into the hole 122. The knob 112Ais coupled to the cap 110A, such that the knob 112A is an externalfeature of the cap 110A, and the cavity 138 is an internal feature ofthe cap 110A. The port boss 114 is configured to be at least partiallyinside the cavity 138 when the cap 110A is in the first position asshown in FIG. 2A. The user can move the cap 110A from the first to thesecond position while the earplug 102 remains in the ear canal, such asto engage in conversation. Likewise, the user can move the cap 110A fromthe second to the first position while the earplug 102 is in the earcanal, such as to block high intensity sound.

In some examples, the sound filter 170 can be coupled with a variety ofother units to attenuate sound. Such units can include an attachment asdescribed above, or a different type of tube or earplug.

FIG. 3A includes a view of an example of a portion of the earplug 102.The shaft 124 is coupled to the flange 104. In one example, the flange104 is positioned at the emitter end 128. The bore 130 extends through acenter of the shaft 124, as shown in FIG. 3A. In the example shown, theshaft 124 is tapered. The outer diameter of the shaft 124 at thereceiver end 126 is greater than the outer diameter of the shaft 124 atthe emitter end 128. The flange 104 can be configured with faces thatare straight, conical, or curved. A shape of the flange 104 can becurved, such as the cup-like shape shown in the example of FIG. 3A. Aninner concave surface of the flange 104 can be configured to accommodatethe foam body 106A, and an external surface of flange 104 can beconfigured to engage the ear canal.

FIG. 3B includes an end view of an example of a portion of the earplug102. The bore 130 has a bore diameter 158.

FIG. 4 illustrates an example of the foam body 106B. The foam body 106Bhas a channel 160 extending through its center as shown in the exampleof FIG. 4. The shaft 124 extends into the channel 160. A diameter of thechannel 160 corresponds to an outer diameter of the shaft. In oneexample, the diameter of the channel 160 is less than the outer diameterof the shaft, such that the channel 160 is expanded from its restingstate. In another example, the diameter of the channel 160 can be thesame as or larger than the outer diameter of the shaft. In one example,the foam body 106B comprises memory foam such as polyurethane (PU). Invarious examples, foam body 106B is fabricated of polyvinyl chloride(PVC) or phthalate-free vinyl.

A shape of the foam body 106B has a larger outer diameter at one end, asshown in FIG. 4. The size and shape of the foam body 106B is configuredto fit inside the ear canal. The foam body 106B can have a compressedstate or an expanded state. The foam body 106B can become compressedwhen the user presses the foam body 106B between two fingers, forexample. The foam body 106B expands from the compressed state andreturns to a natural configuration when the external compression isremoved.

In FIG. 4, flange 98B is squared at both the inner edge and at the outeredge. Flange 98B can aid in device retention. In some examples, flange98B can be positioned behind the tragus.

The foam body 106B abuts the inner concave surface of the flange 104,such as shown in the example of FIG. 1A. The user can compress the foambody 106B for insertion into the ear canal. In the compressed state, thefoam body 106B allows for easier insertion. The first end of the earplug102 is inserted into the ear canal. The earplug 102 is placed at adesired position in the ear canal. The flange 104 is configured toanchor (e.g., hold in place) the earplug 102. The foam body 106B canexpand from the compressed state to engage the ear canal. The flange 104anchors the earplug 102 in place by engaging the ear canal. The flange104 has an outer surface (e.g., opposite the inner concave surface). Theouter surface of the flange 104 presses against the ear canal having adiameter less than a flange diameter. One or more seals can be createdin the ear canal. A seal can be created by a component of the earplug102 engaging (e.g., pressing against, held in place by friction, ortouching) the ear canal.

The flange 104 engages the ear canal, and creates a first flange seal inthe ear canal. The first flange seal anchors the earplug in place duringinsertion, and attenuates sound. A potential advantage of the presentsubject matter can include that the user may not need to hold theearplug in place while waiting for the foam body 106B to expand. Flange104, in one example, is self-centering in the ear canal and compressiveforces exerted by the foam body are sufficient to maintain an open pathfor audio frequency vibrations notwithstanding contortions of the pathof shaft 124.

The foam body 106B can expand to a size and shape of the ear canal. Assuch, an outer surface of the foam body 106B engages the ear canal. Thefoam body 106B creates a foam body seal. The foam body seal can aid inanchoring the earplug in place during use, and can attenuate sound. Theuser can wear the earplug 102 for long periods of time (e.g., an hour,multiple hours, or for a day), without removing the earplug 102 from theear.

In an example, the outer diameter of the shaft can be different at thereceiver end 126 and the emitter end 128 due to the taper of the shaft124. In an example, the shaft 124 is configured to passively push (e.g.,due to the taper) the foam body 106B toward the first end 108. The foambody 106B is passively pushed toward the flange 104. This enhances thefirst flange seal by encouraging the flange 104 to press into (e.g.,expand into) the ear canal.

The first durometer allows the shaft 124 to bend to conform to anon-uniform shape of the ear canal. The foam body 106B is configured tosupport the shaft 124, such as to prevent the bore 130 from collapsing.As such, the foam body 106B can aid in preventing a blockage of soundthrough bore 130.

FIG. 5A illustrates a portion of the earplug 102, according to anexample. The flange 104 is coupled to the shaft 124. In one example, theflange 104 and the shaft 124 are molded out of the same material assingle piece. The earplug 102 includes a member configured to positionthe foam body at a desired location along the shaft 124. In an example,the member is a secondary flange 162. In other examples, the member is astud, a pin, or other protrusion.

FIG. 5A is a side view of the shaft. In an end view, the secondaryflange 162 has a circular shape. The secondary flange 162 is fixed at anaxial position on the shaft 124. In one example, secondary flange 162 isaffixed along a length of shaft 124 and in other examples, secondaryflange 162 is affixed at or near an end of the length of shaft 124(receiver end 126).

In an example, the foam body 106B (not shown in this view) is positionedbetween the secondary flange 162 and the base plate 118 (not shown inthis view). When the earplug 102 is in the ear canal, the resultingspace (e.g., air gap, air, opening, or recess) between the flange 104located at the emitting end 128 and the foam body 106B can aid inreducing the sound reaching the eardrum.

In an example, a portion of the flange 124 (e.g., the portion of theflange 124 between the secondary flange 162 and emitter end 128 in theexample of FIG. 5A) is configured to conform to a shape of the earcanal. The shape of the ear canal can bend or can narrow. As such, theportion of the flange 124 is configured to be flexible to fit into theshape of the ear canal.

In an example, the ear canal can have an oblong narrowing portion. Theflange 124 can be configured to aid in centering the emitter end 128 inthe ear canal, such as to aid in sound blockage.

FIG. 5B illustrates a portion of the earplug 102, according to anexample. In one example, the earplug 102 includes multiple flanges, suchas an end-flange 104A and a middle-flange 104B. The middle-flange 104Bis positioned between the receiver end 126 and the emitter end 128. Theend-flange 104A is positioned at the emitter end 128. The end-flange104A and the middle-flange 104B are configured to create a seal in theear canal. The end-flange 104A has the same or similar shape as themiddle-flange 104B. In another example, end-flange 104A has a shape orsize different than the middle-flange 104B.

In one example, the earplug 102 can include an arrangement along theshaft 124 including the foam body 106B (not shown) between theend-flange 104A and the middle-flange 104B.

FIG. 5C illustrates a portion of the earplug 102, according to anexample. The secondary flange 162 is positioned at a desired locationalong the length of the shaft 124. In an example, the earplug 102 caninclude multiple secondary flanges 162, such as illustrated in FIG. 5C.The multiple secondary flanges 162 can have varying shapes along thelength of the shaft 124. In an example, each of the multiple secondaryflanges 162 creates a seal in the ear canal. In an example, a space canbe between each of the multiple secondary flanges 162. In an example,the multiple secondary flanges 162 can be molded with the shaft 124 as asingle piece, such as shown in FIG. 5C.

In another example, the multiple secondary flanges 162 can be separatepieces from the shaft 124. The multiple secondary flanges 162 caninclude a circular opening. In this example, the multiple secondaryflanges 162 can be coupled to the shaft 124. The multiple secondaryflanges 162 can be positioned on the shaft 124 using the circularopening. The multiple secondary flanges 162 can be stacked, such as toprovide an arrangement like that of the example of FIG. 5C. The multiplesecondary flanges 162 are stacked by placing a secondary flange on topof another with a spacer member in between.

In an example, the foam body 106B is made of a single piece of foam. Or,for example, the foam body 106B can be comprised out of multiple piecesof foam, such that there are multiple foam members positioned along thelength of the shaft 124. In one example, the multiple foam members canbe positioned next to one another. In an example, the multiple foammembers can be separated, such as by the middle-flange 104B or thesecondary flange 162. In an example, the foam body 106B is replaceable,such that the user can select a different foam body 106B for differentuses of the earplug 102.

FIG. 6 illustrates an example of a tool 602. The tool 602 includes aflange-compression member 604, a handle 606, and a bore-pin 608. Thehandle 606 is coupled to the flange-compression member 604. The bore-pin608 is coupled to the handle 606. The bore-pin 608 is positioned atleast partially inside of the flange-compression member 604, asillustrated in FIG. 6. The tool 602 has a metal material. A size of thebore-pin 608 corresponds to the bore 130. A size of theflange-compression member 604 corresponds to the flange 104. A diameterof the flange-compression member 604 is less than a diameter of theflange 104. In one example, bore-pin 608 is omitted and a flangedstructure can be folded into cylinders to allow for replacement orcustomization. In one example foam body 106B can be replaced from thefilter end using tool 602.

Tool 602 can be provided as a component of a kit including various sizefoam body elements, shafts, filters and other components. A kit canallow a user to customize an ear plug to accommodate a wide variety ofear canal sizes, shapes, and suited for a specific sound environment.

In an example, the tool 602 has a plastic material (e.g., the secondmaterial).

FIG. 7 illustrates an assembly method 700, according to an example. At710, the filter stem 132 is inserted into the bore 130.

At 720, an assembly is inserted onto the tool 602. The assembly includesa first portion that can include the shaft 124 and the flange 104, and asecond portion that can include the filter stem 132 and the cap 110A.The emitter end 128 of the shaft 124 is slid onto the bore-pin 608, andthe flange 104 is compressed into the flange-compression member 604. Thebore-pin 608 is positioned inside the bore 130. The bore-pin 608 isconfigured to support the shaft 124.

At 730, the foam body 106B is slid onto the shaft 124. For example, thefoam body 106B is inserted onto the handle 606, such that the handle 606is inside of the channel 160. The foam body 106B is pushed over theflange-compression member 604, and then the foam body 106B is pushedonto the shaft 124. The assembly is removed from the tool 602.

Notes & Examples

The sound attenuation system can include one or more components, such asthe earplug 102 or a pair of earplugs coupled to each other by a cord.

In an example, the flange 104 is a separate piece from the shaft 124.

In an example, the cap 110A can be coupled to the base plate 118 usingone or more connecters. In an example, the connecter can include aplastic member having a spring constant. In an example, the earplug 102can include two or more plastic members positioned along a circumferenceof the cap 110A. The plastic member can be configured such that the cap110A is substantially parallel to the base plate 118 in the firstposition and in the second position. In this example, the space 172 is aspace between the port boss 114 and the cavity 138 in the secondposition. The cap 110A can be pushed onto the port boss 114, toconfigure the cap in the first position. There can be a frictionconnection between the cavity 138 and the port boss 114 in the firstposition. The friction connection can oppose the force of the plasticmember having the spring constant, such as to retain the cap 110A in thefirst position. The user can move the cap 110A to the second position,such as by overcoming the friction connection.

In an example, the connector can include a cord.

In an example, the cap 110A is removable from the earplug 102.

FIG. 8 illustrates an example of a sound filter. In the exampleillustrated, joint 120 is coupled to cap 110B and coupled to knob 112B.Cap 110B, in the example shown has an offset portion. The offset portionprovides a gap between base plate 118 and cap 110B to facilitatemanipulation by a user.

The above detailed description includes references to the accompanyingdrawings, which form a part of the detailed description. The drawingsshow, by way of illustration, specific embodiments in which theinvention can be practiced. These embodiments are also referred toherein as “examples.” Such examples can include elements in addition tothose shown or described. However, the present inventors alsocontemplate examples in which only those elements shown or described areprovided. Moreover, the present inventors also contemplate examplesusing any combination or permutation of those elements shown ordescribed (or one or more aspects thereof), either with respect to aparticular example (or one or more aspects thereof), or with respect toother examples (or one or more aspects thereof) shown or describedherein. Some examples include the following.

Example 1 can include or use subject matter (such as an apparatus, amethod, or a means for performing acts) such as can include or use asound attenuation system comprising a first end including a shaft and aflange. The flange is coupled to the shaft. The shaft has a firstdurometer. The shaft having a bore between a receiver end and an emitterend. The system comprising a second end including a filter stem coupledto a cap by a joint. The filter stem has a second durometer. The filterstem has a hole between an inlet end and an outlet end. The filter stemhas a port boss. The outlet end is coupled to the receiver end. The capincludes a cavity having a cavity diameter that corresponds to an outerdiameter of the port boss. The joint is configured to allow the cap tohave a first position in which the cap occludes the hole and to have asecond position in which the cap is clear of the hole.

Example 2 can include, or can optionally be combined with the subjectmatter of Example 1, to optionally include a foam body having a channel,the shaft extending into the channel.

Example 3 can include, or can optionally be combined with the subjectmatter of any one of Examples 1 or 2 wherein an outer diameter of theshaft is tapered.

Example 4 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-3, wherein the outer diameter of theshaft at the receiver end is greater than the outer diameter of theshaft at the emitter end.

Example 5 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-4, further comprising a base platecoupled to the filter stem.

Example 6 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-5, wherein the joint is coupled to thebase plate.

Example 7 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-6, further comprising a gap between thebase plate and the cap when in the first position.

Example 8 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-7, further comprising a secondary flangecoupled to the shaft.

Example 9 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-8, wherein the filter stem is at leastpartially inside of the bore.

Example 10 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-9, wherein the flange is curved.

Example 11 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-10, further comprising a foam bodyhaving a channel, the shaft extending into the channel.

Example 12 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-11, wherein the foam body abuts aconcave portion of the flange.

Example 13 can include, or can optionally be combined with the subjectmatter of any one of Examples 1-12, wherein a diameter of the channelcorresponds to an outer diameter of the shaft.

Example 14 can include or use subject matter (such as an apparatus, amethod, or a means for performing acts), such as can include or use asound filter for an earplug, the sound filter comprising a filter stemcoupled to a cap by a joint. The filter stem has a hole between an inletend and an outlet end. The filter stem has a port boss. The joint isconfigured to allow the cap to have a first position in which the capoccludes the hole and to have a second position in which the cap isclear of the hole.

Example 15 can include, or can optionally be combined with the subjectmatter of Example 14, wherein the cap includes a cavity having a cavitydiameter that corresponds to an outer diameter of the port boss.

Example 16 can include, or can optionally be combined with the subjectmatter of any one of Examples 14 or 15, wherein a portion of the filterstem is tapered.

Example 17 can include, or can optionally be combined with the subjectmatter of any one of Examples 14-16, wherein the hole includes a firstchamber having a first diameter and a second chamber having a seconddiameter.

Example 18 can include, or can optionally be combined with the subjectmatter of any one of Examples 14-17, wherein the hole includes a thirdchamber having a third diameter.

Example 19 can include, or can optionally be combined with the subjectmatter of any one of Examples 14-18, wherein the first diameter is lessthan the second diameter.

Example 20 can include, or can optionally be combined with the subjectmatter of any one of Examples 14-19, further comprising a knob coupledto the cap, the knob on an opposite side of the cap as the cavity.

Example 21 can include, or can optionally be combined with the subjectmatter of any one of Examples 14-20, further comprising a base platecoupled to the filter stem, a gap between the base plate and the cap,wherein the joint is coupled to the base plate and wherein the gap ispresent in the first position.

Example 22 can include, or can optionally be combined with the subjectmatter of any one of Examples 14-21, wherein the base plate includes anotch.

Example 23 can include or use subject matter (such as an apparatus, amethod, or a means for performing acts), such as can include or use asound attenuation system comprising a foam body having an inner channelextending between a receiver end and an emitter end. The body has acylindrical portion coaxial with the channel. The body includes anelastic foam configured to return to a natural configuration after anexternal compressive force is applied and removed. The system includes ashaft configured for placement within the channel between the receiverend and the emitter end. The shaft includes an inner bore alignedaxially and includes a flange affixed proximate the emitter end, andwherein the shaft is configured to maintain a configuration determinedby the foam body and wherein the inner bore remains open.

Example 24 can include, or can optionally be combined with the subjectmatter of Example 23, wherein the foam body includes polyvinyl chlorideor polyurethane.

Example 25 can include, or can optionally be combined with the subjectmatter of any one of Examples 23 or 24, wherein the foam body has aflange at the receiver end.

Example 26 can include, or can optionally be combined with the subjectmatter of any one of Examples 23-25, wherein the shaft includessilicone.

Example 27 can include, or can optionally be combined with the subjectmatter of any one of Examples 23-26, wherein the flange is curved.

Example 28 can include, or can optionally be combined with the subjectmatter of any one of Examples 23-27, further comprising a filter coupledto engage with the bore, the filter having an axial lumen configured toconvey audio frequency vibrations.

Example 29 can include, or can optionally be combined with the subjectmatter of any one of Examples 23-28, wherein the axial lumen includes anorifice.

Example 30 can include, or can optionally be combined with the subjectmatter of any one of Examples 23-29, wherein the axial lumen includes atleast two chambers.

Example 31 can include, or can optionally be combined with the subjectmatter of any one of Examples 23-30, further including a base platecoupled to a receiver end of the filter.

In the event of inconsistent usages between this document and anydocuments so incorporated by reference, the usage in this documentcontrols.

In this document, the terms “a” or “an” are used, as is common in patentdocuments, to include one or more than one, independent of any otherinstances or usages of “at least one” or “one or more.” In thisdocument, the term “or” is used to refer to a nonexclusive or, such that“A or B” includes “A but not B,” “B but not A,” and “A and B,” unlessotherwise indicated. In this document, the terms “including” and “inwhich” are used as the plain-English equivalents of the respective terms“comprising” and “wherein.” Also, in the following claims, the terms“including” and “comprising” are open-ended, that is, a system, device,article, composition, formulation, or process that includes elements inaddition to those listed after such a term in a claim are still deemedto fall within the scope of that claim. Moreover, in the followingclaims, the terms “first,” “second,” and “third,” etc. are used merelyas labels, and are not intended to impose numerical requirements ontheir objects.

The above description is intended to be illustrative, and notrestrictive. For example, the above-described examples (or one or moreaspects thereof) may be used in combination with each other. Otherembodiments can be used, such as by one of ordinary skill in the artupon reviewing the above description. The Abstract is provided to allowthe reader to quickly ascertain the nature of the technical disclosure.It is submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims. Also, in theabove Detailed Description, various features may be grouped together tostreamline the disclosure. This should not be interpreted as intendingthat an unclaimed disclosed feature is essential to any claim. Rather,inventive subject matter may lie in less than all features of aparticular disclosed embodiment. Thus, the following claims are herebyincorporated into the Detailed Description as examples or embodiments,with each claim standing on its own as a separate embodiment, and it iscontemplated that such embodiments can be combined with each other invarious combinations or permutations. The scope of the invention shouldbe determined with reference to the appended claims, along with the fullscope of equivalents to which such claims are entitled.

1. A sound-attenuation system for placement at least partially in an earcanal of a person, the system comprising: a shaft having a firstdurometer and having a bore between a receiver end of the shaft and anemitter end of the shaft; a middle flange positioned on the shaftbetween the receiver end and the emitter end, wherein the middle flangehas a cup-like shape having a convex external surface facing the emitterend of the shaft and configured to engage the ear canal to create a sealin the ear canal and wherein the middle flange has a concave innersurface facing the receiver end of the shaft; and a foam body having achannel, wherein the foam body is mounted on the shaft between theconvex external surface of the middle flange and the emitter end of theshaft with the shaft extending through the channel.
 2. Thesound-attenuation system of claim 1, wherein the first durometer isbetween shore 30 and 40 to allow the shaft to bend to conform to anon-uniform shape of the ear canal.
 3. The sound-attenuation system ofclaim 1, wherein the foam body is configured to support the shaft toprevent the bore from collapsing.
 4. The sound-attenuation system ofclaim 1, wherein the shaft further includes a second curved flangelocated at the emitter end of the shaft and having a convex externalsurface facing the emitter end and a concave inner surface towards thereceiver end, and wherein the foam body is mounted on the shaft betweenthe convex external surface of the middle flange and the concave innersurface of the second flange.
 5. The sound-attenuation system of claim1, wherein the shaft is tapered from a first outer diameter at thereceiver end of the shaft to a second outer diameter at the emitter endof the shaft, wherein the second outer diameter is smaller than thefirst outer diameter.
 6. The sound-attenuation system of claim 1,wherein the foam body includes a plurality of pieces of foam positionednext to each other on the shaft.
 7. The sound-attenuation system ofclaim 1, further comprising: a filter stem having a second durometer,wherein the filter stem includes: a hole between an inlet end and anoutlet end, wherein the outlet end of the filter stem is coupled to thereceiver end of the shaft, and a port boss; and a cap coupled to thefilter stem by a joint, wherein the cap includes a cavity having acavity diameter that corresponds to an outer diameter of the port boss,and wherein the joint is configured to allow the cap to have a firstposition in which the cap occludes the hole and to have a secondposition in which the cap is clear of the hole.
 8. A sound-attenuationsystem for placement at least partially in an ear canal of a person, thesystem comprising: a shaft having a first durometer and having a borebetween a receiver end of the shaft and an emitter end of the shaft; amiddle flange positioned on the shaft between the receiver end of theshaft and the emitter end of the shaft, wherein the middle flange isconfigured to engage the ear canal to create a seal in the ear canal;and a plurality of secondary flanges located on the shaft closer to theemitter end of the shaft than the middle flange.
 9. Thesound-attenuation system of claim 8, wherein the middle flange has aconvex external surface facing the emitter end of the shaft and aconcave inner surface facing the receiver end of the shaft.
 10. Thesound-attenuation system of claim 8, wherein the plurality of secondaryflanges and the shaft are molded as a single piece.
 11. Thesound-attenuation system of claim 8, wherein the plurality of secondaryflanges is molded separately from the shaft and includes a circularopening configured to fit around an outside diameter of the shaft suchthat the plurality of secondary flanges is positioned on the shaft viathe circular opening.
 12. The sound-attenuation system of claim 8,wherein each one of the plurality of secondary flanges includes acircular opening configured to fit around an outside diameter of theshaft, the sound-attenuation system further comprising a first spacer,wherein the plurality of secondary flanges includes a first secondaryflange and a second secondary flange, and wherein the first secondaryflange and the second secondary flange are stacked onto the shaft nextto each other with the first spacer located between the first secondaryflange and the second secondary flange.
 13. The sound-attenuation systemof claim 8, wherein the plurality of secondary flanges includes a firstsecondary flange and a second secondary flange, wherein the firstsecondary flange includes a first diameter, wherein the second secondaryflange includes a second diameter, and wherein the first diameter islarger than the second diameter.
 14. The sound-attenuation system ofclaim 8, further comprising: a filter stem having a second durometer,wherein the filter stem includes: a hole between an inlet end and anoutlet end, wherein the outlet end of the filter stem is coupled to thereceiver end of the shaft, and a port boss; and a cap coupled to thefilter stem by a joint, wherein the cap includes a cavity that fits overthe port boss, and wherein the joint is configured to allow the cap tohave a first position in which the cap occludes the hole and to have asecond position in which the cap is clear of the hole.
 15. Asound-attenuation system for placement at least partially in an earcanal of a person, the system comprising: a shaft having a firstdurometer and having a bore between a receiver end of the shaft and anemitter end of the shaft; a first flange positioned on the shaft betweenthe receiver end of the shaft and the emitter end of the shaft; a foambody having a channel, wherein the foam body is mounted on the shaftbetween the first flange and the receiver end of the shaft with theshaft extending through the channel of the foam body.
 16. Thesound-attenuation system of claim 15, wherein the first flange is flatand has a circular circumference.
 17. The sound-attenuation system ofclaim 15, further comprising: second flange located at the emitter endof the shaft and having a convex external surface facing the emitter endof the shaft and a concave inner surface towards the receiver end of theshaft, wherein a space between the second flange and the foam body isconfigured to reduce sound that reaches an eardrum of the person whilethe sound-attenuation system is at least partially in the ear canal ofthe person.
 18. The sound-attenuation system of claim 15, wherein thefirst durometer is between shore 30 and 40 to allow the shaft to bend toconform to a non-uniform shape of the ear canal.
 19. Thesound-attenuation system of claim 15, wherein the foam body includes aplurality of pieces of foam positioned next to each other on the shaft.20. The sound-attenuation system of claim 15, further comprising: afilter stem having a second durometer, wherein the filter stem includes:a hole between an inlet end and an outlet end, wherein the outlet end ofthe filter stem is coupled to the receiver end of the shaft, a portboss, and a base plate; and a cap coupled to the filter stem by a joint,wherein the cap includes a cavity having a cavity diameter thatcorresponds to an outer diameter of the port boss, wherein the joint isconfigured to allow the cap to have a first position in which the capoccludes the hole and to have a second position in which the cap isclear of the hole, and wherein the foam body is mounted on the shaftbetween the first flange and the base plate of the filter stem.